Coating Particulate Material via Atomized Spray and Feedback Control
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Solution Overview
Problem
Existing methods for coating landscaping materials like wood mulch lack efficient control over the coating process, particularly in ensuring uniform application and adjustment based on the volumetric feed rate of particulate material, leading to inconsistencies in coating distribution and residence time within the mixing chamber.
Innovation Solution
An apparatus with a mixer and agitator system that includes a coating feed system delivering an atomized spray, controlled by sensors measuring the particulate material's feed rate, ensuring precise adjustment of coating flow and distribution through a network of spray nozzles, and utilizing a pressurized water carrier for efficient atomization without the need for compressed gas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a multistage mixing bowl is used for continuous mixing of colorant with mulch material, then mixing capability is improved, but control precision over coating flow and distribution deteriorates
Solution Approach 1:
The system incorporates sensors that detect the volumetric feed rate of particulate material and provide feedback to a controller. The controller automatically adjusts the coating feed rate to match the feed rate, ensuring precise control over coating distribution while maintaining continuous mixing operation.
Solution Approach 2:
The coating delivery system transitions from static batch application to dynamic continuous spraying. The atomized spray nozzles deliver coating material continuously as the particulate material moves through the mixing chamber, allowing real-time adjustment of coating flow to match varying feed rates.
2Device complexity
If coating is applied without adjustment based on volumetric feed rate, then process simplicity is maintained, but coating uniformity deteriorates
Solution Approach 1:
Sensors measure the volumetric feed rate of particulate material entering the mixing chamber and provide this information to a controller. The controller automatically adjusts the coating feed rate accordingly, maintaining coating uniformity without requiring complex manual intervention or overly complicated equipment.
Solution Approach 2:
The system uses sensors and controllers to automatically monitor and adjust the coating process based on actual feed conditions. This self-regulating mechanism maintains coating uniformity without requiring constant operator attention or complex procedural interventions.
3Ease of manufacture
If compressed gas is used for atomization, then atomization capability is achieved, but system complexity and cost increase
Solution Approach 1:
The system uses hydraulic pressure from a liquid carrier (water or other liquid) instead of pneumatic compressed gas to achieve atomization. The pressurized liquid flows through the atomizing nozzle, creating a fine spray of coating material without requiring compressed air or gas systems, thereby reducing complexity while maintaining effective atomization.
4Ease of operation
If coating feed rate is not adjusted to match feed rate, then operational simplicity is maintained, but processing efficiency deteriorates
Solution Approach 1:
The controller receives feedback from sensors about the volumetric feed rate and automatically adjusts the coating feed rate to match. This maintains operational simplicity from the user perspective while significantly improving processing efficiency by ensuring optimal coating application at all times.
Solution Approach 2:
Manual adjustment mechanisms are replaced with an automated control system that uses sensors and electronic control to adjust coating feed rate. This substitution improves processing efficiency while maintaining ease of operation, as the system self-regulates without requiring manual intervention.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution achieves uniform coating distribution, reduces processing time, and enhances adhesion and uniformity of the coating on particulate materials by accurately matching coating flow with the feed rate, resulting in a more efficient and consistent coating process.
Implementation Method 1
The coating is delivered as an atomized spray directed towards the mixing particulate material. The pressurized carrier may be provided at relatively high pressure, preferably at least about 689.5 kPa (100 psi).
Data Source
AI summary
A method and apparatus are defined for coating a particulate material. The apparatus includes a mixer having a mixing chamber. A quantity of particulate material is fed into an inlet of the mixing chamber. An agitator is provided for mixing and conveying the particulate material. A feed system is also provided for delivery of a coating into the mixing chamber. The coating is delivered as an atomized spray directed at the mixing particulate material within the mixing chamber. A controller is provided for adjusting the flow of the coating into the mixing chamber based on the volumetric feed rate of the particulate material.